Exercise mat

ABSTRACT

An exercise mat comprising: a bottom layer; and a top layer comprising an absorbent material and a traction enhancing material printed on the top layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is continuation of U.S. patent application Ser. No.13/728,221, filed Dec. 27, 2012, which, in turn, is based on and derivesthe benefit of the filing date of U.S. Provisional Patent ApplicationNo. 61/580,961, filed Dec. 28, 2011. The entire content of thisapplication is herein incorporated by reference in its entirety.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-6 depict various views of an exercise mat, according to allembodiment of the present invention.

FIG. 7 depicts three layers of an exercise mat, according to anembodiment of the present invention.

DETAILED DESCRIPTION OF SEVERAL EMBODIMENTS

FIGS. 1-6 depict various views of an exercise mat 100, according to anembodiment of the invention. FIG. 1 depicts a top-down view of anexercise mat 100 according to an embodiment of the present invention.FIG. 2 depicts a bottom view of the exercise mat 100. FIGS. 3-6 depictside views of the exercise mat 100. The exercise mat 100 may be placedon a flat surface by a user to provide cushioning and grip, allowing theuser to more easily and effectively perform exercises (e.g., yoga,etc.). The exercise mat 100 can comprise several layers of varyingmaterials and structures disposed atop one another. For example, FIG. 7depicts three layers that can be part of the exercise mat 100: a bottomlayer 703 (e.g., of natural rubber), a top first material 702 (e.g., ofpolyester nylon blend microfiber knitted fabric), and a top secondmaterial 701 (e.g., printed material in silicone, acrylic, TPE material,or any combination thereof).

FIG. 1 depicts a rectangular exercise mat 100 of sufficient size tosupport a typical user's body through a wide range of exercisepositions. Example sizes may include, but are not limited to, widths of24 inches to 30 inches and lengths of 70 inches to 78 inches. Although arectangular exercise mat 100 is shown in FIG. 1A, it should be notedthat the exercise mat 100 may have other shapes, such as a square,circle, or oval, or any other shape or design. Embodiments of theexercise mat 100 may be constructed in such a way that the exercise mat100 may be machine washed, tumble dried, or folded, or any combinationthereof. Embodiments of the exercise mat 100 may be made suitable foruse on various surfaces, comprising: hard floors, carpeted floors, othermats (e.g., rubber, PVC, TPE, and/or EVA mats), or other surfaces, orany combination thereof.

The exercise mat 100 may comprise a top layer. In some embodiments, thetop layer may be made of an absorbent fabric material. For example, thetop layer may be made of an absorbent fiber, micro fiber, super microfiber, and/or nano fiber fabric made of 50-100% polyester and/or 50-100%nylon, a blend of regenerated cellulose or polyester fibers, or anycombination thereof Other material types and compositions are possible.In some embodiments, the top layer may be assembled using warp knittedconstruction, which may result in a top layer with non-running edges. Anabsorbent top layer may absorb moisture such as the perspiration of auser who is exercising on the exercise mat 100. The top layer may alsobe treated with an antimicrobial agent. Examples of antimicrobial agentsmay comprise silver based antimicrobial and/or 3-trimethoxy silyl propyldimethyl octadecyl ammonium chloride. However, other antimicrobialagents may also be employed. (ft should be noted that any layer of anyexercise mat described herein may also be treated with an antimicrobialagent.)

The top layer may comprise a second material which may be printed orotherwise applied to a surface of the top layer. The second material maybe a material that can provide friction and/or traction. The secondmaterial may be used by a user to prevent slipping on the top layer ofthe exercise mat 100 or it may be placed in contact with a floor toprevent slipping of the exercise mat 100 itself. The second material maybe a PVC and phthalate free acrylic material, a PVC and phthalate freesilicone material, or any other material, or any combination thereof. Insome embodiments, the second material may be printed onto the top layer.In the example of FIG. 1, the second material 110 is printed in apattern along two sides of the exercise mat 100. This pattern andpositioning may provide grip surfaces for a user's hands and/or feetwhen the user is exercising on the exercise mat 100. For examples ofsuitable traction enhancing materials and applications, see U.S. Pat.No. 7,137,157, the entirety of which is incorporated by referenceherein.

The exercise mat 100 can also have a bottom layer. This bottom layer canprovide friction and/or traction (e.g., in wet and/or dry conditions),so that when it is placed in contact with a floor by a user, theexercise mat 100 does not slide when the user utilizes the exercise mat100 (e.g., for yoga or another exercise). The bottom layer can alsoprovide cushioning for a user of the exercise mat 100. In someembodiments, the bottom layer may be provided with a textured surface toenhance grip. The bottom layer may be made of a thermoplastic elastomer,polyvinyl chloride, polyurethane, natural rubber, synthetic rubber,rubber blends. EVA foam, or another material which provides cushioning,or any combination thereof. In other embodiments, the bottom layer maybe made of rubber, including natural rubber, synthetic rubber, or ablend of the two, or mix of natural rubber, synthetic rubber andthermoplastic elastomers as well as the above-mentioned materials, orany combination thereof. In some embodiments, the bottom layer may alsobe made of a suitable material which can help the exercise mat 100 holdits shape, provide cushioning, provide flexibility, provide wear andtear resistance, or provide support, or any combination thereof: or amaterial that bonds well with the top layer; or any combination thereof.The bottom layer may also be treated with an antimicrobial agent.Examples of antimicrobial agents may comprise: silver basedantimicrobial and/or 3-trimethoxy silyl propyl dimethyl octadecylammonium chloride. However, other antimicrobial agents may also beemployed. (It should be noted that any layer of any exercise matdescribed herein may also be treated with an antimicrobial agent)

The various layers described above may be bonded to one another usingany suitable bonding technique. In some embodiments, the layers may havethermoplastic bonding properties that cause adjacent layers to bond withone another when heated. For example, a rubber bottom layer may bethermally bonded to a fabric top layer. In this case, one method ofmanufacture may comprise preparing and mixing a rubber compound that mayserve as the bottom layer. After mixing, the rubber compound may becalendared or flattened to a desired width and thickness, formed intothe bottom layer, and fed into an oven with a fabric top layer forcuring (e.g., rubber mixing and a calendaring machine may be used toform a thin sheet of rubber). Pressure may be applied to the top fabricand the bottom rubber sheet before and/or while they are fed into theoven (e.g., by calendaring the fabric and rubber sheet together). Heatmay be applied to the top and bottom layers, which may cause the top andbottom layers to bond to one another and may also cause curing and/orfoaming of the rubber. The top and bottom layers may be transported on abelt though heated chamber(s).

In another example, a thermoplastic elastomer and/or synthetic rubberbottom layer may be thermally bonded to a fabric top layer. In thiscase, the top and bottom layers may be formed as in the rubber exampleset forth above or by any other method. A thin film of thermoplasticelastomer may be applied between the top layer and bottom layer in someembodiments. The top and bottom layers, and the thin film between theselayers, if applicable, may be fed into an oven and heated for curingand/or foaming. Pressure may be applied to the top and bottom layers,and a film, if applicable, before and/or while they are fed into theoven. Alternatively, layers may be bonded using other adhesives such asglues and/or mechanical connections. In addition, any combination ofthese methods or any other method may be utilized.

In addition to bonding, manufacturing processes for embodiments of theexercise mat 100 may comprise printing and/or application of the secondmaterial to the first material of the top layer. The top second materialmay be applied in ink form using a printing process in some embodiments.For example, in some embodiments an ink of the second material may heprinted onto the surface of the first material, flash dried, reprinted,and cured, using, for example, a heated chamber. In other embodiments,printing may be done utilizing screen printing, where screens may beplaced on the top layer and squeezies may be used to print the ink onthe top layer and then cured through a hot chamber. For example, asilicone ink may be printed onto the surface of the first material usingthis process and cured at approximately 200° C. for approximately 90seconds. After curing, the exercise mat 100 may be aired out. In someembodiments, the printed layer may be approximately 5%, the fabric layermay be approximately 27% and the bottom layer may he approximately 68%.

Note that the terms “top layer” and “bottom layer” in the embodimentsabove are used for ease of explanation only. Either the top layer or thebottom layer may be placed in contact with a floor by a user, with theopposite side forming an exercise surface for the user. This may allow auser to use different layer characteristics to enhance differentexercises. For example, a user may use the top layer, which may havemoisture absorbing properties, as an exercise surface when the useranticipates sweating. The user may use the bottom layer, which may havehigh friction and/or cushioning properties, as an exercise surface whenthe user does not anticipate sweating. A user may also use either orboth of the top layer and bottom layer for other purposes not limited toexercise.

Example Embodiments

In some embodiments, the following may be utilized: The bottom layer maybe a foamed natural rubber based compound with 3-trimethoxy silyl propyldimethyl octadecyl ammonium chloride as an antimicrobial, anti fungalagent. The top layer may be a warp knitted 80% super micro polyester,20% Nylon 300 grams per square meter fabric, treated with ionic silverfor antimicrobial properties. Acrylic based ink may be printed on thetop layer using a screen printing technique. The size may beapproximately 26 inches by approximately 71 inches, although any sizemay be utilized.

In some embodiments, the following manufacturing method may be utilized:An absorbent fabric, such as a seaisland yarn may be warp knitted, dyed,finished and sueded on both sides. A natural rubber compound may beprepared using various fillers, foaming, antimicrobial, antioxidizing,or odor absorbing agents, or any combination thereof The rubber compoundmay be mixed and calendared onto a conveyer belt, where the super microfiber fabric may be fed together with the flattened rubber layer andboth the layers may be heat bonded by passing in or through an oven forapproximately 5 to 7 minutes under approximately 120 to 150 degree C.heat. During this process the rubber may become bonded to the fabric aswell as becoming cured and foamed. The laminated material may be cooleddown and wound on a roller and taken to a die cutting machine, where thelaminated material may be cut into a mat shape (e.g., approximately 26inches by 71 inches. although any size may be utilized). The laminatedmat may then be printed with acrylic based printing ink (e.g.,throughout the entire mat, on one or both ends of the mat). Two strokesof print may be applied and the material may be passed in or through anoven (e.g., using a conveyer belt) for curing the printing ink atapproximately 170 to 200 degree C. temperature and approximately 45 to120 seconds of time. The finished mat may be cooled down, rolled, andpacked.

Conclusion

While various embodiments have been described above, it should beunderstood that they have been presented by way of example and notlimitation. It will be apparent to persons skilled in the relevantart(s) that various changes in form and detail may be made thereinwithout departing from the spirit and scope. In fact, after reading theabove description, it will be apparent to one skilled in the relevantart(s) how to implement alternative embodiments. Thus, the presentembodiments should not be limited by any of the above-describedembodiments.

In addition, it should be understood that any figures which highlightthe functionality and advantages are presented for example purposesonly. The disclosed methodology and system are each sufficientlyflexible and configurable such that they may be utilized in ways otherthan that shown.

Further, the purpose of any Abstract of the Disclosure is to enable theU.S. Patent and Trademark Office and the public generally, andespecially the scientists, engineers and practitioners in the art whoare not familiar with patent or legal terms or phraseology, to determinequickly from a cursory inspection the nature and essence of thetechnical disclosure of the application. An Abstract of the Disclosureis not intended to be limiting as to the scope of the present inventionin any way.

Although the term “at least one” may often be used in the specification,claims and drawings, the terms “a”, “an”, “the”, “said”, etc. alsosignify “at least one” or “the at least one” in the specification,claims and drawings.

Additionally, the term “comprising” or similar terms in thespecification, claims and drawings should be interpreted as meaning“including, but not limited to.”

Finally, it is the applicant's intent that only claims that include theexpress language “means for” step for be interpreted under 35 U.S.C.212, paragraph 6. Claims that do not expressly include the phrase “meansfor” or “step for” are not to be interpreted under 35 U.S.C. 212,paragraph 6.

What is claimed is:
 1. An exercise mat comprising: a bottom layer; and atop layer comprising an absorbent material and a traction enhancing,material printed on the top layer.
 2. The exercise mat of claim 1,wherein the bottom layer comprises: a thermoplastic elastomer, apolyvinyl chloride, a polyurethane, a natural rubber, a syntheticrubber, a rubber blend, or an EVA foam, or any combination thereof. 3.The exercise mat of claim 1, wherein the bottom layer is configured toprovide traction when placed in contact with a surface.
 4. The exercisemat of claim 1, wherein the absorbent material comprises: an absorbentfiber, a micro fiber, a super micro fiber, a nano fiber fabric made of50-100% polyester and/or 50-100% nylon, or a blend of regeneratedcellulose or polyester fibers, or any combination thereof
 5. Theexercise mat of claim 1, wherein the absorbent material comprises a warpknitted material.
 6. The exercise mat of claim 1, wherein the tractionenhancing material comprises a PVC and phthalate free acrylic material,or a PVC and phthalate free silicone material, or any combinationthereof.
 7. The exercise mat of claim 1, wherein the traction enhancingmaterial is disposed on an outer surface of the absorbent material in apattern.
 8. The exercise mat of claim 1, wherein the traction enhancingmaterial is printed on an outer surface of the absorbent material. 9.The exercise mat of claim 1, wherein an inner surface of the top layerand an inner surface of the bottom layer are laminated to one another.10. The exercise mat of claim 1, wherein the top layer and/or the bottomlayer comprises an antimicrobial agent.
 11. The exercise mat of claim 1.wherein the exercise mat is constructed and arranged to be machinewashed and/or tumble dried.
 12. An exercise mat comprising: a bottomlayer configured to provide traction when placed in contact with asurface; and a top layer comprising a warp knitted absorbent materialand a traction enhancing material printed on an outer surface of theabsorbent material; wherein an inner surface of the top layer and aninner surface of the bottom layer are laminated to one another.
 13. Theexercise mat of claim 12, wherein the bottom layer comprises: athermoplastic elastomer. a polyvinyl chloride, a polyurethane, a naturalrubber, a synthetic rubber, a rubber blend, or an EVA foam, or anycombination thereof.
 14. The exercise mat of claim 12, wherein theabsorbent material comprises: an absorbent fiber, a micro fiber, a supermicro fiber, a nano fiber fabric made of 50-100% polyester and/or50-100% nylon, or a blend of regenerated cellulose or polyester fibers,or any combination thereof.
 15. The exercise mat of claim 12, whereinthe traction enhancing material comprises: a PVC and phthalate freeacrylic material, or a PVC and phthalate free silicone material, or anycombination thereof.
 16. The exercise mat of claim 12, wherein thetraction enhancing material is disposed on an outer surface of theabsorbent material in a pattern.
 17. The exercise mat of claim 12,wherein the traction enhancing material is printed on an outer surfaceof the absorbent material.
 18. The exercise mat of claim 12, wherein aninner surface of the top layer and an inner surface of the bottom layerare laminated to one another.
 19. The exercise mat of claim 12, whereinthe top layer and/or the bottom layer comprises an antimicrobial agent.20. The exercise mat of claim 12, wherein the exercise mat isconstructed and arranged to be machine washed and/or tumble dried. 21.An exercise mat comprising: a bottom layer configured to providetraction when placed in contact with a surface, the bottom layercomprising a foamed natural rubber-based compound with an antimicrobialagent comprising 3-trimethoxy silyl propyl dimethyl octadecyl ammoniumchloride; and a top layer comprising a warp knitted absorbent materialcomprising 80% super micro polyester and 20% nylon, the top layertreated with an antimicrobial agent comprising ionic silver; and atraction enhancing acrylic material printed on an outer surface of thetop layer.
 22. The exercise mat of claim 21, wherein the tractionenhancing material comprises: a PVC and phthalate free acrylic material,or a PVC and phthalate free silicone material, or a combination thereof.23. The exercise mat of claim 21, wherein the traction enhancingmaterial is disposed on an outer surface of the absorbent material in apattern.
 24. The exercise mat of claim 21, wherein the tractionenhancing material is printed on an outer surface of the absorbentmaterial.
 25. The exercise mat of claim 21, wherein the top layer and/orthe bottom layer comprises an antimicrobial agent.
 26. The exercise matof claim 21, wherein the exercise mat is constructed and arranged to bemachine washed and/or tumble dried.
 27. The exercise mat of claim 21,wherein an inner surface of the top layer and an inner surface of thebottom layer are laminated to one another.
 28. A method of manufacturingan exercise mat, comprising: pouring, a bottom layer onto a conveyorbelt, the bottom layer comprising a foamed natural rubber-based compoundwith an antimicrobial agent comprising 3-trimethoxy silyl propyldimethyl octadecyl ammonium chloride; pouring a top layer onto thebottom layer, the top layer comprising a warp knitted absorbent materialcomprising 80% super micro polyester and 20% nylon; heating the bottomlayer and top layer in an oven, wherein the inner surface of the bottomlayer and the inner surface of the top layer are laminated to each otherin a mat; cooling the mat; wounding the mat on a roller cutting the matinto a rectangular shape; printing a traction enhancing acrylic materialon an outer surface of the top layer of the mat; and heating the mat inan oven such that the traction enhancing acrylic material is laminatedto the outer surface of the top layer of the mat.
 29. The method ofclaim 28, wherein the bottom layer and top layer are laminated togetherby being heated in the over for approximately 5-7 minutes atapproximately 120-150 degrees C.
 30. The method of claim 28, wherein thetraction enhancing acrylic material is laminated to the outer surface ofthe top layer of the mat by being heated in the over for approximately45-120 seconds at approximately 170-200 degrees C.